Professional Documents
Culture Documents
Chapter 7
Service and
Maintenance
Different degrees of normal wear of parts of crane (including the engine) will happen during operation; the
user shall use and maintain the crane regularly in strict accordance with the operation manual of crane and
engine, and inspect and maintain the crane regularly to meet the requirement of local environment
department if necessary. After adjustments and repairs have been made the crane shall not be
71
operated until all guards have been reinstalled, safety devices reactivated, and maintenance
equipment removed.maintenance of the crane shall conform to ANSI B30.5:2007 section 5-2.3
Notes:
A crane which has been idle for a period of one month or more, but less than 6 months, shall be given an
inspection conforming with requirements of paragraph (d)(3) of 1910.180 and paragraph (g)(2)(ii) of
1910.180 before placing in service.
A crane which has been idle for a period of six months shall be given a complete inspection conforming
with requirements of paragraphs (d) (3) and (4) of 1910.180 and paragraph (g)(2)(ii) of 1910.180 before
placing in service.
Standby cranes shall be inspected at least semiannually in accordance with requirements of paragraph (d)(3)
of 1910.180 and paragraph (g)(2)(ii) of 1910.180. Such cranes which are exposed to adverse environment
should be inspected more frequently.
7.1
7.1.2
It is recommended to select long-acting and four season general antifreeze (ethylene glycol) or long-acting
antifreeze with equivalent boiling point, freezing point, PH value and also can adapt the same lowest
temperature. The ratio of antifreeze and water is usually 1:1.
7.1.3
Caution: Please refer to the operation manual of the hydraulic torque converter for detailed
information on the hydraulic oil for the hydraulic torque converter. Use the hydraulic
oil of the grade recommended in the operation manual and change periodically
according to maintenance period.
7.2
Lubrication
Proper lubrication to the vehicle can reduce the frictional resistance and mechanical wear of the vehicle,
prevent the malfunctions as well as prolong the service life of the vehicle.All moving parts of the crane for
which lubrication is specified shall be regularly lubricated. All control mechanisms for excessive
wear of components and contamination by lubricants or other foreign matter.Lubricating
systems shall be checked for proper delivery of lubricant. Care shall be taken to follow the manufacturers
recommendations as to the points and frequency of lubrication, maintenance of lubricant levels, and types
of lubricant to be used. Machinery shall be stationary while lubricants are being applied and protection
provided Crane shall be stationary while lubricants are being applied and protection provided.and:1Set all
controls in the off position and ensure all operating features are secured from inadvertent motion by brakes,
pawls, or other means2Lower the boom to the ground, if possible, or otherwise secure against dropping
72
7.2.1
Lubrication Table
SN
Number of
oil sites
Lubrication
interval
3106mile
(5000km)
GL-5 85W/90
(10000km)
3106mile
(5000km)
3106mile
(5000km)
932mile
(1500km)
3106mile
(5000km)
6213mile
Transmission
Category of
lubricants (grease)
Add oil
1
6213mile
Method of
lubrication
(10000km)
31065mile
73
Change oil
Inject
with
grease gun
ZL-2 lithium-based
grease
Inject
with
grease gun
ZL-2 lithium-based
grease
Inject
with
grease gun
ZL-2 lithium-based
grease
Inject
with
grease gun
ZL-2 lithium-based
grease
Add oil
GL-5 85W/90
Change oil
SN
Number of
oil sites
Lubrication
interval
Method of
lubrication
Category of
lubricants (grease)
Inject
with
grease gun
ZL-2 lithium-based
grease
(50000km)
3106mile
(5000km)
3106mile
(5000km)
GL-5 85W/90
6213mile
(10000km)
3106mile
(5000km)
3106mile
(5000km)
(10000km)
11
12
12
13
1553mile
(2500km)
3106mile
(5000km)
3106mile
(5000km)
3106mile
(5000km)
Change oil
Replenish oil
10
W/40
engine oil
1
6213mile
14
Add oil
GL-5 85W/90
(10000km)
Change oil
1
6213mile
10
Add oil
CH-4
Change oil
Inject
with
grease gun
ZL-2 lithium-based
grease
Inject
with
grease gun
ZL-2 lithium-based
grease
Inject
with
grease gun
ZL-2 lithium-based
grease
Add oil
GL-5 85W/90
6213mile
(10000km)
Change oil
Caution:
(1) Confirm the work hours of engine by the engine time counter on tachometer, then perform
of Engine Operation
specific maintenance according to Maintenance regulations of engine
engine
Manual.
(2) The lubricant of power takeoff is from the lubricants of transmission box, oil level depends on
the height of oil filling of transmission box.
(3) Clean the grease adhering to the around of screw plug and check for any oil leakage after
replenishing or changing grease.
(4) For the new vehicle that break-in period is completed, drain the old oil and add thin engine oil to
rear axle when changing gear oil of front and rear axle for the first time; put up front and rear
wheels of the crane
crane,, start engine, engage the gear, clean the rear axle after running for about 5
74
7.2.2
Chassis need
needss lubrication per month
Caution:
(1) Drain the gear oil when it is still hot. For the new vehicle that break-in period is completed,
drain the old oil and add thin engine oil to rear axle when changing oil for the first time; put up
front and rear wheels of the crane
crane,, start engine, engage the gear, drain the wash oil after
running for about 5 minutes, then add new gear oil.
(2) Add grease until it spills from the oil level hole of main reduction gears and wheel.
75
Slide fork of
drive shaft
2)
Universal joint
bearing of drive shaft
Rear suspension
3)
Steering system
Steering drag link
Steering
cylinder
4)
76
7.2.3
Chassis need
needss lubrication every 500 hours
Twist the drain plug of oil pan and filter and drain the engine oil when
engine stops and oil is still hot. Then tighten the drain plug, add engine
oil via oil filler to the full scale of oil level dipstick.
Oil volume for changing
Oil pan: about 4.7 Usgal (18L)
Oil filter: 0.264 Usgal (1L)
The engine is running idle for several minutes after replenishing engine oil. About 30 minutes after engine
77
Oil viscosity
Above 40
20W/40
40~-10
10W/40
Below -10
5W/30 or 10W/30
7.2.4
Chassis need
needss lubrication every three months
Inspection hole
Twist the plug of inspection hole of front and rear axle, check if the oil level is flush with oil filler, and add
gear oil via inspection hole until it spills from the hole.
7.2.5
Chassis need
needss lubrication every six months
78
For new vehicle, change gear oil after working for 250 h.
7.2.
7.2.66
Hydraulic oil
The hydraulic oil tank on this product has been filled with hydraulic oil at delivery. Oil grade: L-HV32.
Caution: This product uses full hydraulic drive, so quality, viscosity and cleanliness of hydraulic
oil is crucial to normal operation of the crane. Neglect of hydraulic oil change by users can result
in various malfunctions of the machine easily and greatly reduce its working life. Our company
will not take any consequences caused by users
users failure to change and filter hydraulic oil as
required by this manual.
7.2.
7.2.66.1 Filter or change period chart of hydraulic oil
Date of
delivery
7.2.
7.2.66.2
200 working
hours
Filter or
change oil
Every 6 months
Filter or
change oil
1)
Change the hydraulic oil in the hydraulic oil tank first. Drain the hydraulic oil in the oil tank, and
remove the main oil return pipe. Clean the oil tank and the filter strictly. You can clean them once
with chemical cleaning agent with a level of contamination by solid particles not exceeding 18/15,
and flush with fresh hydraulic oil with a level of contamination by solid particles not exceeding
18/15 after cleaning and air drying, and then drain the flushing oil and fill fresh hydraulic oil.
2)
Start the engine and run it at low speed; let the oil pump start to work; operate mechanisms
respectively to allow fresh hydraulic oil to drive out used oil in circuits of the system in sequence
(the used oil drained must not flow into the oil tank) until fresh oil flows out of the main oil
return pipe. Then, stop oil pump rotation. Remember to refill the hydraulic oil tank with fresh
hydraulic oil continuously while changing oil in circuits so as to prevent oil pump empty suction.
Connect the main oil return pipe with the oil tank. Finally, set all components to initial working
state and refill the oil tank with hydraulic oil up to the specified level.
3)
Standard for hydraulic oil change: Change hydraulic oil immediately when number of
contamination particles per milliliter of hydraulic oil exceeds any of the following values.
10um
3000
20um
300
30um
100
40um
30
50um
10
100um 1
Caution:
A.
Whenever the hydraulic oil is found seriously contaminated, filter or change promptly.
B.
D.
Service time of hydraulic oil must not exceed 24 months. If the time limit is exceeded,
continued use of the hydraulic oil is not allowed even if it has been filtered.
E.
Check the oil cylinder for any air bubble and improve the sealing performance. Make the
cylinder operate alternately at the maximum speed and please ensure the piston cylinder
extend and retract to both ends to remove the gas in the cylinder completely.
Liquid thermometer
7.2.
7.2.66.3 Hydraulic oil temperature
On the liquid thermometer there are graduations through which you can observe hydraulic oil temperature.
The maximum working temperature of the hydraulic oil is 80.
7.2.
7.2.66.4 Hydraulic oil volume
Check oil level when the crane is on traveling state, observe temperature of the hydraulic oil and check oil
level via the graduated liquid level gauge and liquid thermometer, and replenish hydraulic oil when oil
level is lower than the lowest scale line. Hydraulic system for proper oil level: daily, when used.
7.2.
7.2.66.5 Table of hydraulic oil characteristics and grades
Characteristics and grades of hydraulic oils required according to ambient temperature (by area and season)
are listed in the table below. Please read it carefully when selecting hydraulic oil.
Ambient
temperature: above
40
Ambient
temperature:
-20~40
Ambient
temperature:
above -30
Ambient
temperature: below
-30
GB11118.1-94
GB11118.1-94
GB11118.1-94
SH 0358-95
L-HM
L-HV
L-HS
Aircraft fluid
Viscosity grade
68
32
22
10
180
160
140
92
61.2-74.8
28.8-35.2
19.8-24.2
(5010 (50)
-18
-30
-50
130
130
Item
Reference standard
Variety
95
710
Item
Ambient
temperature: above
40
Ambient
temperature:
-20~40
Ambient
temperature:
above -30
-9
-33
-45
Pour point ()
Ambient
temperature: below
-30
7.2.
7.2.77 Gear oil
Use the gear oil of the grade recommended in this manual. This product has been filled with SY1172-80
90# industrial gear oil at delivery. Natural parameters of the oil are as follows:
Kinematic viscosity (100), mm/s
Composition
13.5<24.0
165
7.2.
7.2.77.1
Date of
delivery
Oil change
Every 12 months
Oil change
Caution:
A.
If the gear oil is found seriously contaminated, change even if oil change period is not
reached.
B.
Check oil level on a regular basis. If the oil level is below the specified position, refill.
C.
D.
Please use the recommended gear oil according to ambient temperature. Use of
nonconforming gear oil or gear oil of inappropriate viscosity will cause damage to the
reduction unit.
7.2.
7.2.77.2
711
Explanation: Demand quantity of gear oil is approx. 1/2 US gal (1.5 L).
Explanation: Demand quantity of gear oil is approx. 1US gal (4.5 L).
7.2.
7.2.88 Grease
Use the grease of the grades recommended in this manual. This product uses ZL-2 or ZG-3 grease.
Filling method: Smear or inject with grease gun.
712
Parameter
Appearance
Drop point
()
Moisture (%)
ZL-2 Grease
175
ZG-3
Grease
90
2.5
Category
7.2.
7.2.99
SN
Lubrication
interval
Lubrication method
Sort of grease
Every 10 days
ZL-2 Grease
Sliders on boom
Every 10 days
ZL-2 Grease
Every 10 days
ZL-2 Grease
Every 10 days
Smear
ZL-2 Grease
Every month
ZL-2 Grease
Sheave blocks
auxiliary hooks
Every 10 days
ZG-3 Grease
Every day
ZL-2 Grease
Every month
ZL-2 Grease
Every 10 days
ZL-2 Grease
10
Every 6 months
Pour directly
11
Boom spindle
Every day
ZL-2 Grease
12
Every 6 months
Pour directly
13
Wire ropes
Every 10 days
Daub
ZG-3 Grease
14
Every 10 days
ZL-2 Grease
(shafts)
of main
and
713
Lubrication diagram
14
13
12
11
10
2
10
713
Caution:
7.3
A.
B.
Sliding surfaces not listed in the table shall also be greased periodically.
C.
D.
When adding grease to bushings, shafts, and bearings, fill until used grease can be
forced off.
E.
If a part of piston rod of the boom luffing cylinder is exposed with the boom kept
on its support, grease the exposed part monthly.
F.
Inspection procedure for cranes in initial inspection shall be pay attention to the following:
a. Checked main
conponents .
15
The tire pressure has a possibility to be enlarged because of friction heating during
traveling hours. The tire pressure also has a possibility to be enlarged by overspeed
traveling. In this condition, it is prohibited to outlet the air inside of the tire while slowing
down or switching off is allowed until the tire is cooling down.
The charging pressure shall be measured by precise tire gauge after the tire is cooling
down (once for a certain time).
It is very dangerous to outlet air from the tire that has not been cooled down, which shall
be prohibited. The tire pressure will be decreased and temperature will be increased while
traveling is still going on, at this condition, tire will break down.
Insufficient air pressure over low air pressure will increase the tire bending which could
cause the friction between tire surface and road. This will over enlarge the tire tension,
which increases the danger of friction and damage.
Appropriate air pressure there will be a largest contact surface between tire surface and
road at appropriate pressure, which will increase tire life.
Over large air pressure
over large air pressure will decrease the tire bending which
could cause the squeezing between tire and tire thread to accelerate the wearing of tire
surface.
7.
7.44
17
7.
7.44.1 Periodic inspection of chassis
Periodic inspection is not only to prolong the service life of the crane but to increase the safety and
comfort of crane operation. Dated records for periodic inspections shall be made on critical items
such as brakes, crane hooks, ropes, hydraulic and pneumatic cylinders, and hydraulic and
pneumatic relief pressure valves. Records shall be kept where they are available to appointed
personne by the manufacturer.
Warning: the items in the following table must be recorded and well preserved.
Periodic inspection items in the following table are listed for the cranes that work 250 hours a
month in temperature of -10 35 and in less-dust condition. Inspection and maintenance
intervals shall be shortened according to actual situation if the crane is operated in harsh
conditions or in coastal areas, deserts and cold regions.
7.3
Inspection procedure for cranes in initial inspection shall be pay attention to the following:
g. Checked main
conponents .
18
The tire pressure has a possibility to be enlarged because of friction heating during
traveling hours. The tire pressure also has a possibility to be enlarged by overspeed
traveling. In this condition, it is prohibited to outlet the air inside of the tire while slowing
down or switching off is allowed until the tire is cooling down.
The charging pressure shall be measured by precise tire gauge after the tire is cooling
down (once for a certain time).
It is very dangerous to outlet air from the tire that has not been cooled down, which shall
be prohibited. The tire pressure will be decreased and temperature will be increased while
traveling is still going on, at this condition, tire will break down.
Insufficient air pressure over low air pressure will increase the tire bending which could
cause the friction between tire surface and road. This will over enlarge the tire tension,
which increases the danger of friction and damage.
Appropriate air pressure there will be a largest contact surface between tire surface and
road at appropriate pressure, which will increase tire life.
Over large air pressure
over large air pressure will decrease the tire bending which
could cause the squeezing between tire and tire thread to accelerate the wearing of tire
surface.
7.
7.44
7.
7.44.1 Periodic inspection of chassis
Periodic inspection is not only to prolong the service life of the crane but to increase the safety and
comfort of crane operation. Dated records for periodic inspections shall be made on critical items
such as brakes, crane hooks, ropes, hydraulic and pneumatic cylinders, and hydraulic and
pneumatic relief pressure valves. Records shall be kept where they are available to appointed
personne by the manufacturer.
Warning: the items in the following table must be recorded and well preserved.
Periodic inspection items in the following table are listed for the cranes that work 250 hours a
month in temperature of -10 35 and in less-dust condition. Inspection and maintenance
intervals shall be shortened according to actual situation if the crane is operated in harsh
conditions or in coastal areas, deserts and cold regions.
7.
7.44.1 Periodic inspection of chassis
Periodic inspection is not only to prolong the service life of the crane but to increase the safety and
comfort of crane operation. Dated records for periodic inspections shall be made on critical items
such as brakes, crane hooks, ropes, hydraulic and pneumatic cylinders, and hydraulic and
21
Warning: the items in the following table must be recorded and well preserved.
Periodic inspection items in the following table are listed for the cranes that work 250 hours a
month in temperature of -10 35 and in less-dust condition. Inspection and maintenance
intervals shall be shortened according to actual situation if the crane is operated in harsh
conditions or in coastal areas, deserts and cold regions.
Inspection interval
New
Every
Month
Every 3
months
Every 6
months
Every
year
60
hours
250
hours
Engine revolutions
exhaust condition
and
Valve clearance
Every
250
hours
Every
500
hours
Every
1000
hours
Engine
filter
and
of
Caution:
(1) Refer to the Engine operation manual for the service and maintenance of parts and components of
engine assembly.
22
Inspection interval
New
60
hours
250
hours
Every
Month
Every 3
months
Every 6
months
Every
year
Every
250
hours
Every
500
hours
Every
1000
hours
(2) The additives such as antifreeze, rust inhibitor, preservatives, etc. In coolant liquid and engine oil have
a certain degree of toxicity, so it is necessary to avoid the long-term skin contact. Dispose the additives
according to the local rule of environmental protection if it is not used.
Discharge
cylinder
water
air
Filter
element
in
Clean
wash
or
Replace
Engine oil
Replace
filter
element
Exhaust
sediment
Oil-water
separator
Replace
filter
element
Oil
quantity
and black
color
Replace
Motor system
Air and oil leakage of each
part of motor system
Shaking of transmission
control system
Looseness
of
transmission
connection end
the
shaft
23
Inspection interval
New
60
hours
250
hours
Every
Month
Every 3
months
Swing of transmission
shaft and shaking of spline
Replace
Liquid
level
Replace
Drive system
Looseness,
cracking,
damage and deformation of
every part of front axle and
rear axle
Looseness of wheel nuts
Every
500
hours
Gear oil of
rear axle
Every
250
hours
Looseness of transmission
shafts neck bearing
Liquid
level
Every
year
Shaking of transmission
shafts bearing
Gear oil of
transmission
Every 6
months
Every
1000
hours
Inspection interval
New
Every
Month
60
hours
250
hours
Every 3
months
Every 6
months
Every
year
bearings
Steering system
Performance
steering gear
of
power
Brake system
Air leakage
system
of
brake
Brake performance
25
Every
250
hours
Every
500
hours
Every
1000
hours
Inspection interval
New
60
hours
250
hours
Every
Month
Every 3
months
Every 6
months
Every
year
Brake
chamber
performance
and
the
abrasion of slippers
Every
250
hours
Every
500
hours
Every
1000
hours
Suspension system
Looseness, sharking and
damage of every part of
suspension system
Electrical system
Liquid level of storage
battery
and
Generator
Caution: the inspection of starter and generator shall be conducted after disassembly; replace the
damaged parts.
Pay much attention to installation, demounting, disassembly and reinstallation operate
softly and steadily by applicable tools to avoid damage.
Looseness and damage of
joints of electrical wirings
Chassis accessories
Function and damage of
illuminating system
26
Inspection interval
New
60
hours
Performance of
each
instrument and indicator
light
Functions
switches
of
250
hours
various
Every
Month
Every 3
months
Every 6
months
Every
year
Every
250
hours
Caution: replace the lubricating oil of new power takeoff after 20 hours in use.
Looseness, damage of
exhaust pipe and muffler
Performance
muffler
of
Every
500
hours
exhaust
27
Every
1000
hours